yeah I have some 1/8" that I use to make mounting brackets from. I was thinking 1/16" which is .06".. I'd like some input from Full race and maybe cheapturbo. I know they both are doing custom coolers.

14 gauge seems to be what PWR makes their end tanks out of, or at least from eye balling a few cores that have been threw my shop. Basically you want the thinest material to keep the thermal conductivity high, but thick enough its not impossible to weld.

hmm interesting. I thought for sure you all would use 6061.. Why do you use the others? What rod would you recomend with the 5052? I normally use a 4043 I think. I also have some 5052, should I match the rod to the material?

Wow so your using 1/8" end tanks? That is really heavy. Can you use a normal sheet metal brake to bend them or are you using a press brake?

Aluminum Alloy 6061 has a thermal conductivity of 180 w/m-k
5052 has a thermal conductivity of 137 w/m-k
1100 has a thermal conductivity of 218 w/m-k

6061 and 5052 are both good alloys for this purpose because they are highly corrosion resistant and strong.... using 1100 would scratch too easily despite it having a really good thermoconductivity(its at least 99% aluminum )

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